Numerical Optimization and Manufacturing of the Impeller of a Centrifugal Compressor by Variation of Splitter Blades

Abstract

Design and optimization of centrifugal compressors, based on main blades configuration of impeller have been vastly discussed in open literature, but less researches have addressed splitters. In this research, the impeller of a commercial turbocharger compressor is investigated. Here, profiles of main blades are not changed while the effect of changing the configuration of splitters is studied. An optimization study is performed to find the best configuration using genetic algorithm over a complete operating curve of the compressor. CFD codes with experimental support are used to predict the compressor performance. Quantumetric tests beside destructive analysis of two impellers are implemented for material identification and selection which is necessary for manufacturing. After taking into account structural considerations and approving the safety by numerical simulation, the new impeller is manufactured using 5 axis CNC machine. Non destructive tests are performed for identification of any structural defects. The new impeller is then mounted on a turbocharger shaft and tested experimentally in a wide range of operating conditions, which leads to a design having 2.3% improvement in efficiency. This is an important achievement in all applications of centrifugal compressors, especially in turbochargers.

Flow Simulation and Model Analysis of Efficiency and Pressure Ratio Behaviors in GT4086 Turbocharger Compressor

“…S.A Mousavi and M. Mojaddam optimized different models of impeller designs by using various algorithms and computational fluid dynamics methods, applied on the GT4082. The results show a significant increase in the pressure ratio, efficiency, and extension of the surge point [23][24][25][26][27][28].…”

Improving the Performance of Centrifugal Compressors by Flow Recirculation

“…10). Details of the laboratory equipment are described in the work of Moussavi et al (2016Moussavi et al ( , 2017. All results are plotted in Fig.…”